Paper Authors

David Forsman

Abstract

NOTE: The first page of text has been automatically extracted and included below in lieu of an abstract

Session 3438

Reverse Engineering and Rapid Prototyping: A Senior Level
Technical Elective for Mechanical Engineering Technology Students
and Much More.
David R. Forsman
Penn State Erie, The Behrend College

Abstract

Students in the Mechanical Engineering Technology (MET) program at Penn State Erie, the
Behrend College are highly versed in application oriented computer techniques for problem
solving. Nine years ago, a senior level technical elective was developed that would allow
students with an interest in CAD modeling and design extending beyond the nine credits of
required CAD classes to further their knowledge of the latest technology. This course would
also introduce students to aesthetic and ergonomic design issues, which, while touched upon in
traditional design courses, have never been a major factor in the overall design process. Over
time this course has evolved to one that also covers advanced surface modeling CAD strategies
for geometry creation, both additive and subtractive methods for rapid prototyping and different
methods of reverse engineering existing products. In addition, the acquisition of this technology
and equipment has come to benefit both students in other courses and departments within the
College. It has also become a resource for faculty doing research and local industry as well.
This paper will describe the scope and layout of this class, student projects, and the equipment
used, associated costs of running a laboratory and lessons learned as well as the impact on other
faculty, departments and local industry.

Course Overview

METBD 410 (Rapid Prototyping, a technical elective) has the following Goals/Objectives:
1. Understand the advantages and disadvantages of different additive processes currently on
the market.
2. Reverse engineer a product by digitizing geometry, importing the data into
Pro/ENGINEER and creating a solid model from surfaces.
3. Build the model (Objective 2) on the Z-402 3-D printer and re-digitize the prototype
using a non-contact scanner to verify the geometry against the CAD model. Iterate
through Objective 2 and 3 as needed.
4. Create CNC tool paths for three axis milling operations including volume, local,
conventional, contour and trajectory, using Pro/MFG on the CAD model.
5. Check tool paths for accuracy using Pro/NC-CHECK.
6. Post process all tool paths and execute them on a three axis CNC router.